Factors contributing to US chemical plant process safety incidents from 2010 to 2020

Process safety incidents can result in injuries, fatalities, environmental impacts, facility damage, downtime & lost production, as well as impacts on a company's and industry's reputation. This study is focused on an analysis of the most commonly reported contributing factors to process safety incidents in the US chemical manufacturing industry. The database for the study contained 79 incidents from 2010 to 2019, partly investigated by the Chemical Safety Board (CSB). To be included in the study, the CSB archive of incident investigations were parsed to include only incidents which occurred at a company classified as 325 in the North American Industry Classification System (NAICS), assigned to businesses that participate in chemical manufacturing. For each incident, all of the identified contributing factors were catalogued in the database. From this list of identified contributing factors, it was possible to name the ‘top three’ contributing factors. The top three contributing factors cited for the chemical manufacturing industry were found to be: design; preventive maintenance; and safeguards, controls & layers of protection. The relationship between these top contributing factors and the most common OSHA citations was investigated as well. The investigation and citation history for NAICS 325 companies in the Occupational Safety & Health Administration (OSHA) citations database was then analysed to assess whether there was any overlap between the top reported contributing factors to process safety events and the top OSHA citations recorded for the industry. A database consisting of the inspection and citation history for the chemical manufacturing industry identified by NAICS code 325 was assembled for inspections occurring between 2010 and 2020 (August). The analysis of the citation history for the chemical manufacturing industry specifically, identified that the list of the top contributing factors to process safety incidents overlapped with the most common OSHA violations. This finding is relevant to industry stakeholders who are considering how to strategically invest resources for achieving maximum benefit – reducing process safety risk and simultaneously improving OSHA citation history.     

The effectiveness of U.S. OSHA process safety management inspection – A preliminary quantitative evaluation

This study attempted to evaluate the inspection effectiveness of the U.S. OSHA process safety management (PSM) standard using statistical correlation test. A total of 6578 citations of past 1277 OSHA PSM inspections from 1992 to 2006 were quantitatively compared with the findings of the U.S. Chemical Safety and Hazard Investigation Board (CSB) investigations on root and contributing causes of 19 major chemical accidents. Nonparametric Spearman's coefficient of rank correlation tests showed a moderately strong agreement between OSHA PSM inspection citations and CSB findings at p < .01 significant level, and the degree of agreement increased with time. These results suggested that past OSHA PSM inspections had cited the problems that were the accident root causes, and the effectiveness of PSM citations has been improved as more inspections were conducted since the standard promulgation. However, factors such as standard coverage, inspection frequency, inspection resources allocation, and inspection strategy, were critical for effective PSM standard enforcement and implementation. Future studies should include more aspects of PSM citations and CSB accident investigation data for better evaluation of inspection effectiveness. The results may be valuable to the PSM enforcement policy makers.     

Under-recording of work-related injuries and illnesses: An OSHA priority

IntroductionA 2009 Government Accounting Office (GAO) report, along with numerous published studies, documented that many workplace injuries are not recorded on employers' recordkeeping logs required by the Occupational Safety and Health Administration (OSHA) and consequently are under-reported to the Bureau of Labor Statistics (BLS), resulting in a substantial undercount of occupational injuries in the United States.MethodsOSHA conducted a Recordkeeping National Emphasis Program (NEP) from 2009 to 2012 to identify the extent and causes of unrecorded and incorrectly recorded occupational injuries and illnesses.ResultsOSHA found recordkeeping violations in close to half of all facilities inspected. Employee interviews identified workers' fear of reprisal and employer disciplinary programs as the most important causes of under-reporting. Subsequent inspections in the poultry industry identified employer medical management policies that fostered both under-reporting and under-recording of workplace injuries and illnesses.ConclusionsOSHA corroborated previous research findings and identified onsite medical units as a potential new cause of both under-reporting and under-recording. Research is needed to better characterize and eliminate obstacles to the compilation of accurate occupational injury and illness data.Practical applicationsOccupational health professionals who work with high hazard industries where low injury rates are being recorded may wish to scrutinize recordkeeping practices carefully. This work suggests that, although many high-risk establishments manage recordkeeping with integrity, the lower the reported injury rate, the greater the likelihood of under-recording and under-reporting of work-related injuries and illnesses.     

Occupational electrical injuries in the United States, 1992-1998, and recommendations for safety research

PROBLEM: CFOI and SOII data show that 2,287 U.S. workers died and 32,807 workers sustained days away from work due to electrical shock or electrical burn injuries between 1992 and 1998. METHOD: The narrative, work activity, job title, source of injury, location, and industry for each fatal electrical accident were examined. A primary causal factor was identified for each fatality. RESULTS: Electrical fatalities were categorized into five major groups. Overall, 44% of electrical fatalities occurred in the construction industry. Contact with overhead power lines caused 41% of all electrical fatalities. DISCUSSION: Electrical shock caused 99% of fatal and 62% of nonfatal electrical accidents. Comprising about 7% of the U.S. workforce, construction workers sustain 44% of electrical fatalities. Power line contact by mobile equipment occurs in many industries and should be the subject of focused research. Other problem areas are identified and opportunities for research are proposed. IMPACT ON INDUSTRY: Improvements in electrical safety in one industry often have application in other industries.     

Visibility-related fatalities related to construction equipment

The construction industry annually experiences one of the highest fatality rates among the industrial sectors in the United States. The factors that contribute to this reputation include the nature of the work, human behavior, the tools and equipment involved, and also the compact work zones. Industrial fatalities are investigated by the Occupational Safety and Health Administration (OSHA). While OSHA groups the causes of fatalities into a few general categories, too little information is gleaned to effectively target specific problem areas.To improve safety performance in the construction industry, it is necessary to understand the underlying causes of accidents. With targeted analysis, patterns emerge and causal factors can be identified. These findings may then be used to form the basis for recommendations that will help to improve construction worker safety. Little research has been conducted in this area.Research was conducted that isolated fatalities in which vision or lack of good visibility was the principle factor or contributing cause. The objective of examining the details surrounding these fatalities was to uncover the contributing factors and to identify the agents that compromised visibility. The study identified 659 fatality accidents from a data pool of 13511 OSHA-investigated cases. It was discovered that blind spots, obstructions and lighting conditions were the most common factors contributing to vision-related fatalities. This research also analyzed the specific conditions associated with particular pieces of construction equipment.     

What kinds of injuries do OSHA inspections prevent?

Objective

OSHA's enforcement program is one of the major public efforts to protect American workers. We examine both the scope of injury prevention that inspections can contribute and the types of standards that contribute the most.

Methods

We linked Pennsylvania Department of Labor and Industry files for lost-time injuries and employment to calculate injury rates for 1998-2005 for all single-establishment manufacturing firms. We linked these to OSHA inspection records.

Results

Inspections with penalties did affect injury types unrelated to standards as well as those related. We also found again that citations for violations of the standard requiring personal protective equipment had the largest impact on preventing injuries.

Impact on Industry

Programs requiring protective equipment use deserve added attention from consultants and inspectors. In addition, some inspections spur managers to undertake safety measures that go beyond compliance with standards.     

Road traffic injuries to foreigners in the People's Republic of China, 2000-2008

Introduction: China's rapid motorization has resulted in significant challenges in road safety. Method: Using official national statistics, this study examines road traffic injuries (RTIs) experienced by foreigners in China. The number of foreigners entering China has increased 2.4 times over the study period, from 10.16 million in 2000 to 24.33 million in 2008. Results: From 2000- 2008, the number of road traffic fatalities among foreigners similarly increased 2.5 fold, including 49 fatalities reported in 2008. Nonfatal RTIs during this same time frame increased by a magnitude of 1.8 (126 nonfatal injuries in 2000 to 223 in 2008). Conclusions: This study suggests that the total number of foreigners working or visiting China each year who suffer fatal and nonfatal road traffic injuries is relatively low. Impact on Industry: This study provided evidence suggesting that foreigners visiting or working in China face a relatively low risk of road traffic injuries.     

Measuring mining safety with injury statistics: lost workdays as indicators of risk

PROBLEM: Mining in the United States remains one of the most hazardous industries, despite significant reductions in fatal injury rates over the last century. Coal mine fatality rates, for example, have dropped almost a thousand-fold since their peak in 1908. While incidence rates are very important indicators, lost worktime measures offer an alternative metric for evaluating job safety and health performance. The first objective of this study examined the distributions and summary statistics of all injuries reported to the Mine Safety and Health Administration from 1983 through 2004. Over the period studied (1983-2004), there were 31,515,368 lost workdays associated with mining injuries, for an equivalent of 5,700 person-years lost annually. The second objective addressed the problem of comparing safety program performance in mines for situations where denominator data were lacking. By examining the consequences of injuries, comparisons can be made between disparate operations without the need for denominators. Total risk in the form of lost workday sums can help to distinguish between lower- and higher-risk operations or time periods. METHOD: Our method was to use a beta distribution to model the losses and to compare underground coal mining to underground metal/nonmetal mining from 2000 to 2004. RESULTS: Our results showed the probability of an injury having 10 or more lost workdays was 0.52 for coal mine cases versus 0.35 for metal/nonmetal mine cases. In addition, a comparison of injuries involving continuous mining machines over 2001-2002 versus 2003-2004 showed that the ratio of average losses in the later period to those in the earlier period was approximately 1.08, suggesting increasing risks for such operations. DISCUSSION: This denominator-free safety measure will help the mining industry more effectively identify higher-risk operations and more realistically evaluate their safety improvement programs. IMPACT ON INDUSTRY: Attention to a variety of metrics concerning the performance of a job safety and health program will enhance industry's ability to manage these programs and reduce risk.     

Employers′ knowledge of the hazard communication standard requirements and the perceived barriers to compliance

This study examined employers′ perceived knowledge of the Hazard Communication Standard (HCS) requirements prior to the inspection in which they were cited for an HCS violation. A lack of staff available to implement the HCS program was identified as having a significant impact upon compliance (p < 01). The perceived difficulty with compliance was also examined by the violations received by the organization. Those organizations cited for failing to have a written program identified a lack of staff available to implement the HCS requirements as having a greater impact upon compliance than those not cited for written program violations (p < 05). Suggested methods for improving the overall compliance with the HCS may include using the many compliance resources available through insurance companies, safety organizations, and state programs. Areas for further research include identifying the availability, use, and effectiveness of the outside safety and health compliance resources.     

Worker safety and injury severity analysis of earthmoving equipment accidents

Introduction: Research on construction worker safety associated with construction equipment has mostly focused on accident type rather than injury severity and the embedded factor relationships. Significant variables and their effects on the degree of injury are examined for earthmoving equipment using data from OSHA. Four types of equipment, backhoe, bulldozer, excavator, and scraper are included in the study. Accidents involving on-foot workers and equipment operators are investigated collectively, as well as separately. Methods: Cross tabulation analysis was conducted to establish the associations between selected categorical variables, using degree of injury as a dichotomous dependent variable (fatal vs. nonfatal) and a number of independent variables having different values. Odds ratios were calculated to determine how much a certain variable/factor increases the odds of fatality in an accident, and the odds ratios were ranked to determine the relative impact of a given factor. Results: It was found that twelve variables were significantly associated with injury severity. Rankings based on odds ratios showed that inadequate safety training (2.54), missing equipment protective system (2.38), being a non-union worker (2.26), being an equipment operator (1.93), and being on or around inadequately maintained equipment (1.58) produced higher odds for fatality. Conclusion: A majority of the earthmoving equipment accidents resulted in fatality. Backhoes were the most common equipment involved in accidents and fatalities. Struck-by accidents were the most prevalent and most fatal. Non-OSHA compliant safety training, missing seatbelt, operator not using seatbelt, malfunctioning back-up alarms, and poorly maintained equipment were factors contributing to accidents and fatalities. On-foot workers experienced a higher number of accidents than operators, while fatality odds were higher for the operators. Practical applications: Safety professionals should benefit from our findings in planning and delivering training and providing oversight to workers in earthmoving equipment operations.     

Managing process chemicals,technology and equipment information for pilot plant based on Process Safety Management standard

Injuries, accidents or even fatalities while working in pilot plant are reported worldwide. The OSHA Laboratory Standard and Hazard Communication Standard have been used as a guideline to manage safety of laboratories and pilot plant. In spite of the implementation of these standards, incidents which result in injuries and property loss are continuously occurring. The implementation of OSHA Process Safety Management (PSM) Standard in pilot plant is expected to further reduce the risks of accidents. This paper presents a new system for managing process chemicals, technology and equipment information in pilot plant and the concept is developed based on Process Safety Information (PSI) element of PSM 29 CFR 1910.119(d). It provides organized strategies to manage documentations, communicate information, and written program for maintaining, revising and updating related information. Process and Instrumentation Diagram (P&ID) is used as a foundation for data management. Implementation of this system at the CO₂ Hydrocarbon Absorption System pilot plant as a case study is examined and discussed.     

Evaluating the effectiveness of a logger safety training program

INTRODUCTION: Logger safety training programs are rarely, if ever, evaluated as to their effectiveness in reducing injuries. METHOD: Workers' compensation claim rates were used to evaluate the effectiveness of a logger safety training program, the West Virginia Loggers' Safety Initiative (LSI). RESULTS: There was no claim rate decline detected in the majority (67%) of companies that participated in all 4 years of the LSI. Furthermore, their rate did not differ from the rest of the WV logging industry that did not participate in the LSI. Worker turnover was significantly related to claim rates; companies with higher turnover of employees had higher claim rates. Companies using feller bunchers to harvest trees at least part of the time had a significantly lower claim rate than companies not using them. Companies that had more inspections per year had lower claim rates. CONCLUSIONS: High injury rates persist even in companies that receive safety training; high employee turnover may affect the efficacy of training programs. The logging industry should be encouraged to facilitate the mechanization of logging tasks, to address barriers to employee retention, and to increase the number of in-the-field performance monitoring inspections. Impact on industry There are many states whose logger safety programs include only about 4-8 hours of safe work practices training. These states may look to West Virginia's expanded training program (the LSI) as a model for their own programs. However, the LSI training may not be reaching loggers due to the delay in administering training to new employees and high levels of employee turnover. Regardless of training status, loggers' claim rates decline significantly the longer they work for a company. It may be that high injury rates in the state of West Virginia would be best addressed by finding ways to encourage and facilitate companies to become more mechanized in their harvesting practices, and to increase employee tenure. Increasing the number of yearly performance inspections may also be a venue to reduce claim rates. Future research could investigate in better detail the working conditions of West Virginia loggers and identify barriers to job tenure, particularly for workers whose primary job task is chainsaw operation. A larger-scale study of the effect of performance monitoring inspections on claim rates is also warranted.     

Leadership skills for strengthening jobsite safety climate

Introduction: Construction foremen may lack the leadership skills needed to create a strong jobsite safety climate. Many construction companies address this by sending their lead workers to the OSHA 30-h course; however the course does not include a leadership training module. This article describes the development and pilot testing of such a module and evaluation surveys designed to address this training gap. Methods: A 17-member curriculum development team, numerous subject matter experts, and an instructional design company helped us develop a comprehensive set of teaching resources and a set of survey instruments for evaluating the materials' effectiveness on improving safety leadership and safety climate. All materials and surveys were pilot tested with representative members of the target population. Results: Pilot surveys showed high reliability and data collected on the resulting Foundations for Safety Leadership (FSL) module indicated that the majority of foremen thought the training was helpful or valuable, particularly the discussion questions. The majority said they intended to use the skills on the jobsite. With the exception of the role-play activities, the trainers rated highly all other components, especially the videos and discussion questions. Modifications were made to the training materials and surveys based on pilot test findings. The most important result of the development and pilot testing efforts is that the OSHA Training Institute (OTI) included the FSL as an elective in the OSHA 30-h course. Conclusions: The FSL module fills a needed skills gap by providing safety leadership training to all foremen who might otherwise not have access to it through their company or union. The continued success of the FSL training will be ensured by dissemination via the OSHA 30-h course, an established nationwide safety training program. Practical applications: The FSL training module has already been widely accepted by the construction industry as a useful approach for providing construction foremen/See new abstract lead workers with the knowledge and skills they need to become more effective jobsite safety leaders.     

Effectiveness of primary enforcement safety belt laws and enhanced enforcement of safety belt laws: a summary of the Guide to Community Preventive Services systematic reviews

BACKGROUND: The use of safety belts is the single most effective means of reducing fatal and nonfatal injuries in motor-vehicle crashes. This paper summarizes the systematic reviews of two interventions to increase safety belt use: primary enforcement safety belt laws and enhanced enforcement of safety belt laws. The reviews were previously published in the American Journal of Preventive Medicine. METHODS: We conducted the systematic reviews using the methodology developed for the Guide to Community Preventive Services. RESULTS: These reviews provide strong evidence that primary laws are more effective than secondary laws in increasing safety belt use and decreasing fatalities and that enhanced enforcement is effective in increasing safety belt use. Increases in belt use are generally highest in states with low baseline rates of belt use. DISCUSSION: Primary safety belt laws and enhanced enforcement programs tend to result in greater increases in usage rates for target groups with lower baseline rates. Concerns regarding public opposition to these interventions may impede their implementation in some jurisdictions. However, surveys indicate that a substantial majority of the public supports implementation of both primary laws and enhanced enforcement programs. CONCLUSION: Based on the strong evidence for effectiveness of primary safety belt laws and enhanced enforcement programs, the Task Force on Community Preventive Services recommended that all states enact primary safety belt laws and that communities implement enhanced enforcement programs.     

The impact of macroeconomic and industrial fluctuation on fatalities of construction workers in China

Objective: This study explores the relationship between fluctuation in economic and industrial development and work-related fatalities of Chinese construction workers. Methods: The data for work-related fatalities in housing and civil engineering in China from 1996 to 2016 were tested for fluctuation and trends of both general economic and industry-specific indicators using the Engle-Granger cointegration analysis and the augmented Granger Causality test the with modified Wald method. Results: Both the long-run equilibrium associations and short-run dynamic interactions between construction safety and macroeconomic development in China were determined. According to the estimates, fatalities in the construction industry appeared to be more significantly associated with changes in the gross output value of the industry, and the improvement in the workers' efficiency also contributed to the decline of fatalities. It initially revealed that the changes in growth rate, instead of growth itself, had a more significant influence on construction safety in China, while a marginal decreasing trend of positive effects exerted by the growth can be expected with the gradual maturity of the industry. Significance: The application of econometrical methods explored an untapped data source for gaining an insight into the underlying rules of occurrence of construction fatalities, thus strengthening the body of knowledge of construction safety by providing a new research perspective that some safety indicators can be treated as the macro-level socioeconomic index. Practical applications: The findings reminded policymakers and practitioners to be aware of potential challenges from the slowing or even declining trend facing the industry in the near future, and offered a reference to relevant authorities for establishing a more targeted and effective governance strategy.     

Logging injuries for a 10-year period in Jilin Province of the People's Republic of China

PROBLEM: Logging continues to be a major source of injuries in northeast China. This paper describes logging-related injuries in the Jilin Province of the People's Republic of China. METHODS: Logging fatalities and nonfatal injuries were summarized from 1981 to 1990 in Jilin. Injury data from 1991 for the entire forestry sector in China were also analyzed. RESULTS: Fatalities were mainly from of head injuries and were caused by being struck by an object. Nonfatal injuries were most often to the lower extremities and the head and were normally caused by being struck by an object or a fall or slip. The majority of both fatal and nonfatal logging injuries occurred to workers with less than 1 year of employment and those under 35 years old. Most injuries occurred November through March in Jilin. IMPACT ON INDUSTRY: Patterns of logging injury in Jilin of China were similar, but not identical, to those described in other studies of logging injuries worldwide. Methods found to be effective in reducing logging-related injuries in other parts of the world might be used in China to reduce the injuries associated with logging.     

Data mining for occupational injuries in the Taiwan construction industry

There is a higher rate of occupational injury in the construction industry than most other industries on average. However, steps can be taken to reduce worker risk through effective injury prevention strategies. In this article, association rule mining is employed in identifying the characteristics of occupational injuries in the construction industry. Accident reports during the period 1999–2004 are extracted from case reports of the Northern Region Inspection Office of the Council of Labor Affairs of Taiwan. In addition to general factors, several factors related to weather conditions are included in this article. The results show that there are some patterns of occupational injuries in the construction industry. The effect of rain on the occurrence of fatalities is of great significance. Proposed inspection plans should be in accordance with the type of construction and environmental evaluation. The findings identified in this article provide a direction for more effective inspection strategies and injury prevention programs.     

Safety teams. Government and business organizations want them and use them, but are they legal?

BACKGROUND: Safety teams have become a popular means to recognize and prevent injuries in the workplace. In fact, organizations, such as OSHA, NIOSH, NIEHS, DOE, and the Ohio BWC, not only encourage safety teams, but have implemented them in their organizations. However, safety teams may not be legal as defined by NLRB Act Sections 2(5) and 8(a)(2). OBJECTIVE: To determine whether safety teams are illegal labor organizations. METHODS: A review of government regulations, safety programs, and safety teams was performed to create a framework of what types of safety programs/regulations are requested and/or required by a variety of government agencies. Next, these requirements were compared to existing case law on illegal labor organizations as defined by the NLRB. RESULTS: Most safety teams and programs, even those implemented by the Federal Government, are illegal labor organizations as defined by NLRB Act Sections 2(5) and 8(a)(2). CONCLUSIONS: The Federal Government needs to amend existing legislation and develop a revision of the NLRB Act that would allow safety teams to function legally in organizations without having to meet intrusive, constricting guidelines that may inhibit the value of safety teams. IMPACT ON INDUSTRY: Organizations must be aware that safety teams may be valuable in reducing job-related accidents and injuries but they may be illegal labor organizations.     

Do industrial incidents in the chemical sector create equity market contagion?

IntroductionThis paper examines a number of US chemical industry incidents and their effect on equity prices of the incident company. Furthermore, this paper then examines the contagion effect of this incident on direct competitors.MethodEvent study methodology is used to assess the impact of chemical incidents on both incident and competitor companies.ResultsThis paper finds that the incident company experiences deeper negative abnormal returns as the number of injuries and fatalities as a result of the incident increases. The equity value of the competitor companies suffer substantial losses stemming from contagion effects when disasters that occur cause ten or more injuries and fatalities, but benefit from the incident through increasing equity value when the level of injury and fatality is minor.ConclusionsPresence of contagion suggests collective action may reduce value destruction brought about by safety incidents that result in significant injury or loss of life.Practical ApplicationsThis research can be used as a resource to promote and justify the cost of safety mechanisms within the chemical industry, as incidents have been shown to negatively affect the equity value of the not just the incident company, but also their direct competitors.     

美国职业卫生法规、监管及统计体系

美国是工业发达国家,是世界上最早建立“职业安全和卫生法”的国家之一。基于该法,美国确立以职业安全卫生监察局(OSHA)为执法机构、职业安全卫生复审委员会(OSHRC)为监督机构的职业卫生监管体系;同时,以劳工统计局(BLS)为统计主管机构,建立以“1904规范”为基础的企业雇主对其作业场所职业卫生记录和报告制度,并辅以两种形式的政府主动调查,形成了自下至上和自上至下相结合的调查统计体系。目前,我国职业卫生的调查统计体系尚未形成。因此,需要从工业发达国家的职业卫生法规、监管入手,以系统的方法和思路,分析其调查统计体系,学习工业发达国家的经验。研究结果认为美国的职业卫生统计体系具有上层法律及相关条例完备、组织体系职责分明、形成了政府主动调查与企业记录报告相结合的调查统计体系等明显的特点。